Support devices for a vehicle and related methods

ABSTRACT

A support device having an elongated support member for providing protection to an underside of a vehicle. The vehicle can have one or more pinch welds, such as a vehicle with a unibody chassis. The support device can serve as a rock rail to distribute a point load from an external object, such as a rock or a boulder, to a larger area of the vehicle to minimize high loading forces to a single point. The support device can alternatively be a running board. Brackets can be included for traditional installation or for a blind installation, when using a frame locking bolt with alignment features.

FIELD OF ART

The field of the invention relates to systems and methods for a rock rail and step assist for a vehicle.

BACKGROUND

Vehicles provide transportation for people and objects over distances. Vehicles can be used both on-road and off-road. In off-road uses, vehicles can often come across rocky terrain with outcrops. Additionally, some vehicles may be used for crawling or traversing rock piles and boulders. Traditionally, many vehicles were manufactured using a body on frame construction method. Typical examples of vehicles with body on frame construction methods include pickup trucks, sport-utility vehicles, and other off-road vehicles. Body on frame is where a relatively rigid frame or chassis carries the engine and drivetrain, and a separate body, including the passenger compartment, is mounted to the frame. Vehicles using body on frame have typically been the main type used for traveling off-road. In these types of vehicles, rock rails, or rock sliders, providing impact or sliding protection from rocks can be mounted to the rigid frame. The rock rails can serve as guard rails for the vehicle. Instead of having a rock or boulder contacting the frame or body of the vehicle, the rock rails, located below the frame, can take the contact and help distribute the force of the contact.

However, many vehicles now utilize a unibody chassis, or unitized body, construction method. A unibody chassis vehicle uses a one piece frame and body structure, without a separate frame, although it does not mean that the frame is made from a single piece of metal. For a unibody construction, the entire unitized body is load bearing. Repairs of a unibody structure require more specialization and can be more time consuming than repair to a body on frame due to the entire unitized body being load bearing. Additionally, the unibody structure eliminates the separate frame to which rock rails can be mounted. Instead, on the underside of a unibody chassis vehicle, there are typically pinch welds on either side of the vehicle where sections of the unitized body are joined together. Typically, portions of the pinch welds are reinforced for the ability to use a floor jack to lift the vehicle. However, the pinch welds are typically not as rigid as a frame of a body on frame vehicle and can buckle or fold if subjected to a sufficiently high localized force or load.

Additionally, vehicles with sufficient ground clearance or height to go off-road and use rock rails are typically high from the ground. As such, these vehicles may present a challenge for entry and exit into the passenger compartment. In these types of vehicles, the passenger compartment or compartments may be located at a height, which makes entry and exit challenging for children, the elderly or infirm and even normal abled-body adults.

SUMMARY

Support devices, particularly running boards for use as rock rails, and attached steps for fitment with vehicles are disclosed. In particular, support devices for fitment with unibody vehicles are disclosed. However, the disclosed support devices can optionally be used with a body on frame construction.

U.S. Pat. No. 9,333,919, which is expressly incorporated herein by reference in its entirety, discloses features of support devices and lighting elements usable with the support devices. The features of the present disclosure can be understood in the context on the incorporated reference. For example, mounting brackets and steps can be attached and fixed to an elongated member or be adjustable along the length of the elongated member, as described in the '919 patent.

Additionally, U.S. application Ser. No. 16/059,997, filed Aug. 9, 2018, published as U.S. No. 2019/0047477, which is expressly incorporated herein by reference in its entirety, discloses features of steps for fitment with a vehicle. The features of the steps can be applied to the support device of the present disclosure.

Aspects of the invention include a support device for a vehicle comprising: a support member defined by a plurality of walls including a support wall, the support member being elongated and including a pinch weld channel having a support surface and at least one extended side wall extending from the support surface, and a side channel spaced from the pinch weld channel; wherein the pinch weld channel is located above, elevation-wise, the support wall and the support wall extends from the support surface at an angle to the support wall; wherein the side channel has a recessed groove for receiving a gap filler.

The support wall of the support device can comprise an I-beam cross sectional shape.

A bracket can be welded to or secured to the support member, the bracket can have a mounting flange for mounting the support member to an underside of a vehicle. The bracket can have a flange with bolt holes for receiving fasteners.

Two or more brackets can be welded to the elongate support member or fastened to the elongate support member.

A step can extend laterally from the elongate support member.

A non-metallic gap filler can be located in the pinch weld channel.

A non-metallic side gap filler having a head portion and a stem portion, and wherein the stem portion can be located in the recessed groove of the side channel.

The head portion of the side gap filler can be hollow.

A rib wall can be located internally of a body defined by the plurality of walls. The rib wall can attach to one of the plurality of walls of the support member.

A further aspect of the invention is a support device for a vehicle, said support device comprising: an extruded metallic support member having a body with a length and a top wall having a top wall with a top surface, a top wall first end, and a top wall second end; a rigid extension extending above the top wall top surface at the top wall first end; a side channel having a recessed groove located at the top wall second end and spaced from the rigid extension; a load bearing structure located directly below, elevation-wise, the rigid extension having a surface for transferring a point load on the surface to the rigid extension; wherein the rigid extension has a terminal end that is located above, elevation-wise, the side channel when the support device is mounted to a side of a vehicle.

The load bearing structure can comprise an I-beam cross sectional shape.

A sloped sidewall can be located below, elevation-wise, the side channel.

A bracket can be coupled to or welded to the support member, the bracket can have a flange for attaching the support member to a vehicle.

A step can extend laterally from the elongated support member.

A second bracket can be spaced from the bracket and a third bracket can be spaced from the second bracket.

An edge guard can be located at the terminal end of the rigid extension.

A still yet further aspect of the invention is a support device for a vehicle comprising: a elongated support member having two ends and a sidewall; a bracket fastened to or welded to the sidewall of the support member; a threaded shank of a bolt projecting through an opening of the bracket; a bolt head welded to a bolt head flange and the threaded shank extending from the bolt head; a spacer located between the bolt head and the bracket, and a pin extending from the spacer and through the bolt head flange, said pin being spaced from said threaded shank.

The pin can be press fitted to a bore in the spacer and can extend through an opening in the bolt head flange.

The spacer can a body with a first body portion having a first diameter and a second body portion with a second diameter, and wherein the second diameter can be larger than the first diameter.

An adapter bracket having a first mounting section can be located between the spacer and the bolt head flange.

The adapter bracket can have a slot formed at the first mounting section.

The first mounting section can have a top surface and wherein a bead can be located at the top surface adjacent the slot.

The adapter flange can further comprise a second mounting section spaced from the first mounting section by an intermediate section.

The intermediate section can have a bend comprising a surface and wherein said surface is configured to abut a pinch weld when the support member is mounted to a vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present devices, systems, and methods will become appreciated as the same becomes better understood with reference to the specification, claims and appended drawings wherein:

FIG. 1 is a front plan view of an exemplary embodiment of a support member of a support device of the present disclosure attached to a vehicle.

FIG. 2 is a front plan view of an exemplary embodiment of the support member of the support device of FIG. 1.

FIG. 3 is a front plan view of an exemplary embodiment of a support device comprising a support member, mounting brackets, and a step.

FIG. 4 is a perspective view of a support device according to the embodiment of FIG. 3.

FIG. 5 is a cross-sectional end view of an alternative support member, which can alternatively be referred to as a rock rail.

FIG. 6 is a schematic cross-sectional end view of an underside of a chassis of a vehicle and a rock rail mounted to the vehicle, with an overlay of the two different rock rail embodiments.

FIG. 7 is a schematic cross-sectional end view showing an overlay of the two different rock rail embodiments and with brackets for mounting to an underside of a chassis of a vehicle.

FIG. 8 is a perspective view of a support device with brackets and frame locking bolts for mounting the support device to a vehicle.

FIG. 9 is a perspective view of the support device of FIG. 8 from a different perspective.

FIG. 10 is an enlarged perspective view of a section of the support device of FIG. 8.

FIG. 11 is an end view of the support device of FIG. 8.

FIG. 12 is a frame locking bolt and an adapter bracket usable for mounting the support device of FIG. 8 to an underside of a vehicle.

FIG. 13 is an enlarged perspective view of an adapter bracket provided in accordance with aspects of the invention for use with a frame locking bolt.

FIG. 14 is a perspective view of a frame locking bolt with a spacer.

FIGS. 15A and 15B are perspective view and cross-sectional side view, respectively, of the spacer of FIG. 14 with a pin press fitted into a bore.

FIGS. 16A-16D show a sequence of views of an installation of a frame locking bolt, adapter bracket, and support device of the present invention.

DETAILED DESCRIPTION

The detailed description set forth below in connection with the appended drawings is intended as a description of the presently preferred embodiments of support devices and components thereof provided in accordance with aspects of the present devices, systems, and methods and is not intended to represent the only forms in which the present devices, systems, and methods may be constructed or utilized. The description sets forth the features and the steps for constructing and using the embodiments of the present devices, systems, and methods in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and structures may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the present disclosure. As denoted elsewhere herein, like element numbers are intended to indicate like or similar elements or features.

FIG. 1 is a front partial cross-sectional of an exemplary embodiment of an elongated support member 102 of a support device 100 of the present disclosure attached to a vehicle 10, which is shown in schematic and can represent any number of vehicles, such as SUVs, trucks, cross-overs, and even automobiles. An exemplary embodiment of the support device 100 with the support member 102, brackets 106 a, 106 b, and a step 104 is shown in FIGS. 3 and 4. The support device 100 can also be referred to as a running board. As the support member 102 of the support device 100 is configured to spread a point load, such as when hitting a rock or an outcrop, over a larger range, such as over the length of the support member 102, the support device may be called or considered a rock rail.

In an example, the support member 102 of the support device 100 can be an elongated extruded member, such as an extruded aluminum member having a length that is sufficient for use on a vehicle. With reference to FIGS. 1 and 2, the support member 102 can have a body with a top wall 122, a side wall 124, and a support wall 126. The walls may be have distinct transitions between them or can have smooth transitions between them. More generally, the various walls may be referred to as a first wall 122, a second wall 124, and a third wall 126. As shown, the walls have distinct transitions. The support wall 126 may have an I-beam shape rigid body 126 a with a bottom end 128 and a pinch weld channel 130 at a top end, which is elevated above the bottom end. In an example, the load bearing body part of the I-beam 126 a is arranged to align directly below or subjacent the pinch weld channel 130, which has a planar surface 130 a that is generally orthogonal to the I-beam shape rigid body 126 a. The planar surface 130 a of the weld channel 130 has a width and a length. One or more wall surfaces or wall extensions can extend from the planar surface 130 a to define the channel 130 above the load bearing body 126 a of the I-beam. In some examples, rather than an I-beam shape rigid body, the support wall 126 may have a different shape, such as a tube. If different shapes are used as the load bearing body part, the different shaped part should be made to locate directly below the pinch when installed.

The rock rail 100 can be powder coated to a desired color. In some examples, when the rock rail 100 is mounted to a vehicle, such as to a truck or an SUV, the exterior surface 124 a of the side wall 124 and/or the bottom end 128 of the support member 102 can be expected to rub or bang against a hard surface, such as against rocks and/or outcrops. By using an aluminum material, the support member 102 can resist rust, since no ferrous metal is used that can be exposed to oxidize and rust. In some examples, a sleeve or a strip of stainless steel material having matching shape as the exterior surface 124 a of the side wall 124 may be secured to the exterior surface 124 a, such as by using screws or fasteners to provide a harder surface to resist wear or scrapes.

With reference to FIG. 4 in addition to FIG. 2, the pinch weld channel 130 can extend substantially the length of the support member 102 to support the pinch weld or welds on a typical side of a vehicle, or at least be provided at locations where pinch welds are located on a vehicle. In an example, the pinch weld channel 130 runs the length of the support member 102 and is configured to abut a lower end edge of the pinch weld 12, as shown in FIG. 1. Thus, when mounted, any point load pushing up against the support member 102 will distribute that load along the length of the support member onto or to the length of the pinch weld 12, which typically runs between the front and rear wheel wells of the vehicle 10. This in turn will help to avoid damage to the pinch weld should the vehicle be used off-roading and then coming into contact with rocks or outcrops.

A rib wall 134 (FIG. 2) may extend from the pinch weld channel 130 to the side wall or the second wall 124 of the support member 102 to provide added structural rigidity to the support member 102. In an example, the rib wall 134 extends from the planar surface 130 a of the pinch weld channel 130 towards the second wall 124. In other examples, the rib wall 134 extends from the I-beam rigid body 126 a or at the intersection between the I-beam rigid body 126 a and the planar surface 130 a. The rib wall 134 may be positioned such that it creates a truss structure with the top wall 122, the side wall 124, and the support wall 126. In some examples, there can be two or more internal rib walls 134 to provide added structural rigidity. Each of the two or more internal rib walls can have two ends and the two ends can attach at different internal surfaces of the support member. Optionally, at least two ends of two or more internal rib walls can converge, touch, or originate from generally the same starting point.

In exemplary embodiments, the support member 102 has a cross section with a triangular shape or an inverse trapezoid profile having a hollow interior defined by the top wall 122, the side wall 124, and the support wall 126. For use as a rock rail, the side wall 124 of the support member 102 is preferably angled or tapered relative to the ground to deflect any impact to the rock rail that may hit the side wall 124 from below. When an impact does hit the rock rail squarely from below, such as when a rock hits the bottom end 128 (FIG. 2), then the design of the present support member pushing up against the pinch weld 12 of the chassis will help to disperse the point load to a larger distributed load so as to avoid high impact concentration at a single point.

In an alternative embodiment, the support member 102 may have a different cross-sectional shape, such as a semicircle shape, an irregular shape, or a rectangular shape provided a load bearing body part of an I-beam is aligned with, such as being located subjacent and generally vertically aligned with, a pinch weld channel and the pinch weld when installed to an underside of a chassis. In other words, the support member 102 can have more than three side walls 122, 124, 126 and more than one internal rib wall 134 with at least one of the side walls being a load bearing wall arranged to be inline or aligned with a pinch weld 12, such as being generally arranged along a straight line or generally vertically with the pinch weld so that any load on the support member when pushed from underneath, such as when bottoming out against a rock, can transfer to the pinch weld. As alluded to, a different load bearing structure, such as a heavy-gauge round aluminum pipe or tubing can be used instead of the I-beam shape rigid structure 126 a. In still other examples, the support structure can have a solid body.

In an exemplary embodiment, the support member 102 comprises extruded metal. In a particular example, the support member 102 may be made of or made from extruded aluminum. Additionally, in some embodiments, the support member 102 may comprise a composite material. Alternatively, the support member 102 may be made of a composite material or a rigid polymer, such as polyether ether ketone (PEEK) or ultra-high-molecular-weight polyethylene (UHMW). Optionally, the support member 102 can be made from both a metal material, such as aluminum, and a composite material. As discussed above, a stainless steel cladding or cover may be placed on the exterior of the sidewall 124 to protect the sidewall from direct damage when coming into contact with a rock or other objects.

In fitment or assembly of the support member 102 with a vehicle, the support wall 126 can be positioned or aligned directly underneath the pinch weld 12 of the vehicle such as that load pushing up on the support member is transferred directly and generally vertically to the pinch weld, and distributed over the length or longer range of the support member and length or point on the pinch weld. The pinch weld 12 of the vehicle 10 may join sections of the underside 16 and the side 14 of the vehicle 10. It is recognized as one of the stronger parts of a unibody construction. The pinch weld 12 may fit into the pinch weld channel 130 at the upper end of the support wall 126. The pinch weld channel 130 is sufficiently wide so that the pinch weld fits between the two wall extensions extending vertically from the planar surface 130 a of the pinch weld channel 130. The pinch weld channel 130 can be sized to have a width from approximately 105% to 1000% of a width of the pinch weld 12, or even larger especially when the pin weld is not terminated with an enlarged end. In some embodiments, the wider width of the pinch weld channel 130 may allow for more universal fitment across a range of vehicles having different pinch weld ends.

In an example, a pinch weld gap filler 140 may be placed in the pinch weld channel 130 between the pinch weld 12 and the planar surface 130 a (FIG. 2) of the support member 102. The pinch weld gap filler 140 may be made from a non-metallic material, such as a polymer material or engineered plastic, positioned in the U-shape of the pinch weld channel 130 to ensure continuous support of the pinch weld 12 along the pinch weld channel 130. The pinch weld gap filler 140 can have a thickness, a width, and a length that fit within the pinch weld channel 130. In an example, the pinch weld gap filler 140 can prevent rattling, which may result from metal on metal contact between the pinch weld 12 and the pinch weld channel 130 of the metal support member 102. In some embodiment, the gap filler 140 may be provided in layers of discrete thicknesses to allow for gap adjustments and usable as shims.

Embodiments of the pinch weld channel 130 may be a T groove. The T groove may act to retain the pinch weld gap filler 140 from falling out of the pinch weld channel 130 during transportation prior to final assembly to the vehicle 10. Alternatively, the pinch weld channel 130 may have a different groove shape, such as a U or V shaped groove or a dovetail groove.

With reference again to FIG. 1, the I-beam body 126 a of the support wall 126 can be vertically aligned with the pinch weld 12. That is, the pinch weld 12 and the support wall 126 define a substantially straight line from the vehicle 10 towards the ground with some slight variation contemplated. As such, when the bottom end 128 of the support member 102 is contacted by an external object, such as a rock or a boulder during use, the force of the impact can be transmitted vertically to the pinch weld 12. The vertical alignment and force transmission from the bottom end 128, such as when the bottom end 128 is pushed on or butted up against a rock or an outcrop, to the pinch weld 12 provides the maximum rigidity and point load transfer from a small point or area to a larger range to prevent buckling or folding of the unibody when no support member is incorporated. As such, the support member 102 can serve as a rock rail to protect the vehicle 10. The vertical alignment may prevent side loading of the pinch weld 12 that would contribute to buckling or folding of the pinch weld 12. In some embodiments, the bottom end 128 may have an external radius, or be rounded, in order to roll or slide over rocks.

Adjacent the support wall 126 and extending laterally away from the vehicle 10 is the top wall 122. In some embodiments, the top wall 122 extends radially from the plane define by the load bearing body part 126 a of the I-beam. The top wall 122 may extend from the pinch weld channel 130 and may extend to a side channel 132. The side channel 132 can be located remotely or spaced from the pinch weld channel 130 and can embody a U-shape or a V-shape channel. The top wall can have a first end and a second end. The pinch weld channel can be at the first end while the side channel at the second end. The side channel 132 can have a length and the length of the pinch weld channel 130 can extend generally parallel to one another. The side channel 132 can be sized and shaped to receive a stem 142 b on a side gap filler 142 (FIG. 1) to affix the side gap filler to the support member 102. In other examples, the side channel 132 can embody spaced part holes or recesses that a gap filler can snap or thread into.

In some embodiments, the side channel 132 may be a T-groove. As seen in FIG. 1, the T-groove may further have rounded or radiused bottom. Alternatively, the side channel 132 may have a different groove shape, such as a U or V shaped groove or a dovetail groove. The side channel 132 can be selected to engage a stem 142 b on the side gap filler 142 in a detent-like engagement to enable securement of the side gap filler 142 to the support member 102. In an example, the stem 142 a can have a mushroom head-like structure and can fit into the side channel 132 with retaining lips on the side channel 132 retaining part of the mushroom head.

The side gap filler 142 may be sized and shaped such that a head section 142 a of the side gap filler 142 contacts the side 14 of the vehicle 10 when the support member 102 is fitted to the vehicle. As such, the side gap filler 142, being elongated to extend approximately the length of the support member, held at an end of the top wall 122 may also act to spread any force on the support member 102 from an external object to larger areas or sections of the vehicle 10. By having the side gap filler 142 and the top wall 122 act on the side 14 of the vehicle 10, the force acting on the pinch weld 12 though the support wall 126 can thereby be reduced.

The side gap filler 142 may comprise an external portion or head portion 142 a located between the support member 102 and the vehicle 10, such as for acting to distribute some of the forces acting on the support member to a larger area adjacent the pinch welds. The external portion or head portion 142 a may be joined to an internal portion or stem portion 142 b, which is sized and shaped to fit in the side channel 132. In some embodiments, the external portion or head section 142 a can have a larger cross sectional area than the internal portion or stem 142 b, which is located internally inside the side channel 132. The external portion 142 a may have a semicircle cross-sectional shape. Preferably, the head portion 142 a is rounded or has smooth surfaces for contacting the vehicle. The head portion 142 a can be hollow. Alternatively, the external portion 142 a may have a rectangular or trapezoidal cross-sectional shape. The internal portion 142 b may have a cross-sectional shape corresponding to the side channel 132 for fixation of the side gap filler 142 to the side channel 132. The engagement can be a detent or snap fit arrangement.

In some embodiments, the side gap filler 142 may be made from a polymer material.

The side gap filler 142 may be a compressible elastomer or a semi-rigid to rigid polymer, such as polyether ether ketone (PEEK) or ultra-high-molecular-weight polyethylene (UHMW). In some examples, the surface of the head section 142 a can be corrugated to give when pressed and the internal hollow space can be filled with an elastomeric material. In addition to acting as a cushion and weight distributing member, the side gap filler 142 may serve as a dust seal and prevent dirt or debris from getting between the support member 102 and the vehicle 10.

The side wall 124 of the support member 102 may be located adjacent the top wall 122 and the support wall 126. The side wall 124 may be an externally, or laterally, facing wall of the support member 102 when the support member is mounted to the vehicle 10 (FIG. 1). In other words, the side wall 124 may be the wall that is most visible when looking at the vehicle with the support member 102 from a side of the vehicle. The side wall 124 may have a number of different surface contour, shape, or geometry that is selected to provide structural rigidity for the support member 102. For example, an exterior surface of the side wall 124 may have a curvature or be flat for various reasons, such as ground clearance or aesthetics. Additionally, the exterior surface of the side wall 124, or other parts of the support member 102, can be sized and shaped for fitment with one or more steps 104 as described below with respect to FIGS. 3 and 4. In some examples, additional walls may be incorporated. For example, a short fourth wall may be located between the top wall 122 and the side wall 124 to provide additional lines or enhanced geometrical profile. In the example shown, the fourth wall can be seen adjacent the side channel 132.

The support member 102 may have a raw metal finish of the extruded metal material. In other examples, the support member 102 may be painted, brushed, or power coated with a color or multiple colors to match the vehicle or to provide a contrast with the color of the vehicle. The finish may also include indicia, such as pictures, text, numbers, or combinations thereof.

FIG. 2 illustrates an end view of the support member 102 separated from the vehicle 10 and without the pinch weld gap filler 140 or the side gap filler 142. FIG. 2 also shows a single rib wall 134 with more than one rib wall contemplated.

FIG. 3 illustrates an end view of an exemplary embodiment of a support device 100 comprising a support member 102 and mounting brackets 106 a, 106 b. In some embodiments, the support device 100 can further comprise at least one step 104. For a four-door vehicle, such as a four-door crew cab truck or a four door SUV, the support device 100 can be equipped with two steps 104 so that four steps are provided on two support devices for the four-door vehicle. The steps can be adjustable, slidable, and/or rotatable relative to the body of the support device. For example, each step can have two mounting plates and each mounting plate can be fastened directly to the support member 102, such as to the side wall 124 of the support member. In some examples, the support member 102, such as the side wall 124, can have one or more bolt galleys or channels and the mounting plates at two ends of the step can have bolts or projections that engage and slide within the bolt galleys.

Mounting brackets 106 a, 106 b can be attached to the support member 102 by welding, adhesives, fastening, detents, or combinations thereof. The two mounting brackets 106 a, 106 b represent different shaped structures for attaching the support member 102 to the frame of a vehicle. The two different shaped brackets 106 a, 106 b allow for attachment of mounting flanges on the brackets with different shaped anchors or attachments points on the vehicle. The number of similar or different brackets can vary depending on the vehicle that the support member is to be mounted. Typically the brackets can attach to the vehicle using one or more bolts. In some embodiments, the mounting brackets 106 a, 106 b can be attached to the I-beam of the support wall 126 and on remote ends to a vehicle. In embodiments, the mounting brackets 106 a, 106 b can be attached to the underside 16 of the vehicle to fix the position of the support member 102. The mounting brackets 106 a, 106 b can be slidable or re-positionable along the length of the support member 102 as described in U.S. Pat. No. 9,333,919, the contents of which are expressly incorporated herein by reference.

Additionally, the mounting brackets 106 a, 106 b may help to distribute the force transmitted by a force acting on the support member 102 to the vehicle 10, in addition to the support member 102 distributing the force as discussed above. For example, the point load on the support member, such as when the vehicle hits a rock or an outcrop, can be distributed along the length of the support member to the pinch weld, as discussed above, as well as to the mounting brackets, which distribute the point load to the mounting points of the brackets 106 a, 106 b to the vehicle. As such, the mounting brackets 106 a, 106 b may lessen the force transmitted to the pinch weld 12 by distributing some of the point load to parts of the unibody that the brackets are mounted. The fixation of the mounting brackets 106 a, 106 b to the vehicle 10 and the support member 102 can also help to ensure the force transmitted through the support member 102 is transmitted directly vertically to the pinch weld 12 to prevent buckling or folding of the pinch weld 12.

In embodiments of the support device 100, only one of the bracket type of the two types shown may be used. Alternatively, two or more of the brackets 106 a, 106 b may be used. That is, in some embodiments, only one type of bracket is attached to the support member 102 while in other installations other type of brackets are used. A first type of the brackets 106 a may be a single piece construction. The first type of bracket 106 a may have a through bore for fastening of the first type of bracket 106 a to the vehicle 10. In some examples, the brackets resemble those disclosed in U.S. Pat. No. 9,333,919, previously incorporated by reference.

A second type of the brackets 106 b may have a base 108 and at least one flange 110. The at least one flange 110 may extend perpendicularly from the base 108. The at least one flange may have a through bores or holes for fastening of the second type of bracket 106 b to the vehicle 10.

The brackets 106 a, 106 b can be sized and shaped in order to conform to the underside 16 of the vehicle 10. Thus, different bracket types may be used in order to conform with different sections and different mounting interfaces on the underside 16 of the vehicle 10. The dimensions of the base 108 and the at least one flange 110 of the second type of bracket 106 b may be different from the first type of bracket 106 a in order to fit a different section of the underside 16 of the vehicle 10. The brackets can also have different shapes and different geometries for fitment with different vehicles.

In some embodiments, the support device 100 may comprise a step 104. The step 104 can extend laterally from the support member 102. The step 104 may include a step bar 112 and two side pieces 114. The side pieces 114 may attach to the support member 102 and opposed ends of the step bar 112. The step bar 112 and the two side pieces 114 can be attached together by welding, adhesives, fasteners, detents, or combinations thereof. The step 104 may be attached to the support member 102 by welding, adhesives, fasteners, detents, or combinations thereof. In some examples, the step 104 may be similar to and attaches to the support member 102 in the same manner as those disclosed in U.S. Pat. No. 9,333,919, previously incorporated by reference.

FIG. 4 is a perspective view of a support device or rock rail 100 according to the embodiment of FIG. 3. As shown in FIG. 4, the side pieces 114 of the step 104 may be at an oblique angle relative to the step bar 112 but can be oriented at different angles.

Furthermore, in some embodiments, a cap or end cap can be mounted to each end of the support member 102 to prevent dust and debris from entering the hollow interior of the support member 102. The cap can frictionally engage the exterior and/or interior of the support member 102 or be attached by way of detents, fasteners, such as set screws, or other securement means. In an example, the end caps can be similar to and can attach to the support member as provided in U.S. Pub. No. 2019/0235480, the contents of which are expressly incorporated herein by reference.

In some embodiments, the support member 102 may extend from near one wheel well to near another wheel well of the vehicle 10. Alternatively, the support member 102 may be shorter or can vary. The length of the support member 102 between the two wheel wells and the support member 102 contacting the bottom of the pinch weld can help to distribute a point load on the support member 102, such as when the support member 102 is pushed against a rock when the vehicle is operating off road, to a larger range or larger area of the support member to distribute the force over a larger area of the pinch weld reduce the load on any single point or location.

With reference now to FIG. 5, an alternative support member 102′ is shown along an end cross-section. The present support member 102′ is similar to the support member 102 of FIGS. 1-4 with some variations. In the present embodiment, the body of the support member 102′ is provided with a rigid extension 150 extending above, elevation-wise, the rigid support wall 126. The rigid extension 150 is provided instead of or as an alternative to the pinch weld channel 130 of FIGS. 1-4. In the example shown, the rigid extension 150 can be unitarily formed with the rigid load bearing body 126 a. As further discussed below, the present support member 102′ may be used in non-pinch weld applications, or for automobiles, trucks, or SUVs without pinch welds. For example, the present support member 102′ with the rigid extension 150 may be used with body on frame vehicles.

The present support member 102′ with the rigid extension 150 may also be used on vehicles with pinch welds but wherein the rigid extension 150 is aligned to abut against a frame area of the vehicle adjacent to or next to the base of the pinch weld, instead of bearing directly on an edge of the pinch weld. Thus, rather than the tip of the pinch weld resting against a pinch weld channel surface of the support member as shown in FIG. 1, in the present embodiment the rigid extension 150 extends upwardly to abut a structure area of the vehicle adjacent to the base of the pinch weld, as further discussed below.

In an example, the rigid extension 150 can have a length, or the dimension that extends above the intersection with the top wall 122, that can fit a range of vehicles. The length of the rigid extension 150 can be adjusted, such as trimmed, cut, or ground down, for final fit for the particular job or application. In some examples, the terminal end 150 a of the rigid extension 150 can be provided with shaped contours, recesses, or surfaces to mate, abut, or engage adjacent structure for mounting.

Although not shown, the present support member 102′ can have one or more rib walls for increasing the rigidity of the support member. For example and like the rib wall 134 of FIG. 2, a rib wall can be provided at the intersection between the load bearing body 126 a and the top wall 122 and then extending to the side wall or second wall 124.

The present support member 102′ can include mounting brackets similar to brackets 106 a, 106 b shown in FIGS. 3 and 4, those disclosed in the '919 patent, and alternatives discussed elsewhere herein. Brackets can be incorporated to mount the support member to a side of a vehicle. Further, the present support member 102 may include one or more steps, similar to the step 104 shown in FIGS. 3 and 4.

FIG. 6 is an end cross-sectional view showing a vehicle 10 and the support member 102 of FIGS. 1-4 and the support member 102′ of FIG. 5 with the two support members overlay on top of one another to show how the two may be used or mounted to the vehicle. In practice, only one or the other of the two support members is used at a time for mounting to a side of the vehicle. The present view is shown without mounting brackets for mounting one or the other of the two support members 102, 102′ to the vehicle for clarity.

As shown, both support members 102, 102′ have side channels 132 for use with a side gap filler 142. The side gap filler 142 abuts or rests against the side 14 of the vehicle and is used to avoid metal-on-metal contact. Mounting of the support member 102 of FIGS. 1-4 is discussed extensively above, with reference to FIGS. 1, 3 and 4. When mounting the support member 102′ of FIG. 5, the rigid extension 150 extends upwardly and contacts a frame base 30 on the underside 16 of the vehicle 10, typically adjacent a pinch weld 12. In practice when a floor jack is used to raise the vehicle, the pad on the floor jack typically contacts the same frame base 30 as shown. Thus, it is understood to be a strong rigid part of the vehicle 10 for the rigid extension 150 to abut against as if the support member abuts against the end of the pinch weld 12.

In an example, an edge guard 34 can be provided at the terminal end 150 a (FIG. 5) of the rigid extension 150. The edge guard 34 can be used as a cushion or a shield to avoid metal on metal contact between the rigid extension and the underside of the vehicle. The edge guard 34 may be a compressible elastomer or a semi-rigid to rigid polymer, such as polyether ether ketone (PEEK) or ultra-high-molecular-weight polyethylene (UHMW). The edge guard 34 can have a channel-like shape, such as a U-shape, to cup around the terminal edge of the rigid extension 150 and can be mounted onto the rigid extension prior to mounting the support member 102′ to the vehicle.

The present support member 102′ has a length that extends all or substantially all of the length between the front and rear wheel wells of the vehicle 10. Consequently, the rigid extension 150 of the present support member 102′ abuts the underside of the vehicle 10, at the frame base 30, along a length of the vehicle. Consequently, when the support member 102′ with the rigid extension 150 experiences a point load, such as when pushed from below by a rock, the support member 102′ spreads the point load across a larger area of the vehicle, via the rigid extension 150, and the edge guard 34, contacting the frame base 30 of the vehicle. This allows the point load to spread or be distributed over a greater area, via the rigid extension pushing against the frame base 30, so as to reduce the possibility of overloading a single point of the vehicle and possibly causing damage or buckling to the frame of the vehicle. In other words, when a single point load is extended from below against the support member 102′, the support member will spread the load along the side of the vehicle that contacts the rigid extension 150 to spread the load across the side of the vehicle that can lift the vehicle rather than cause damage or buckling to the vehicle, which may occur if the support member was not present to spread the point load.

FIG. 7 is similar to FIG. 6 but with brackets 106 a, 106 b, which are similar to brackets shown in FIGS. 3 and 4, shown attached to the support member 102. The present view shows the support member 102 of FIGS. 1-4 and the support member 102′ of FIG. 5 overlay on top of one another to show how the two may be used or mounted to the vehicle. In practice, only one or the other of the two support members is used at a time for mounting to a side of the vehicle. The present mounting scheme may be practiced as discussed above with reference to FIGS. 3 and 4.

With reference now to FIG. 8, perspective view of a running board or support device 100 in accordance with further aspects of the invention is shown. In the present embodiment, a support member 152 has two end caps 155, 155 attached at two ends thereof and one or more attachment points 154 for securing the support member 152 to a side of a vehicle, such as between the front and the rear wheel wells.

The present support member 152 can be an extruded metal member that is usable as a running board for supporting an passenger during ingress and egress to and from a vehicle passenger compartment, similar to the running board disclosed in U.S. Pat. No. 9,333,919, previously incorporated by reference. For example, the support member 152 may be used to mount to a Toyota RAV4 or other SUVs and crossovers. The support member 152 has a top surface 156 with optional grooves or projections to facilitate traction, at least one side mounting wall for mounting the one or more attachment points 154, and an opposed side wall, opposite the mounting wall. The shape of the support member 152 can be non-circular. In an example, the support member is extruded from aluminum and has a plurality of side walls defining a body and the walls can include bolt galleys for mounting fasteners. One or more ribs may be incorporated internally of the body of the support member.

As further discussed below, each of the one or more attachment points 154 can include brackets 158 and frame locking bolts (FLBs) 160 for securing the brackets 158, and hence the support member 152, to the side of a vehicle. In some examples, rather than the running board type support member 152 shown, the rock-rail type support member 102 of FIGS. 1-4 and support member 102′ of FIG. 5 can be used with the one or more attachment points 154 shown and described herein. Thus, the particular shape, length, and surface contours of the support member 152 can vary.

FIG. 9 is a rear perspective view of the support device or running board 100 of FIG. 8. As shown, three attachment points 154 are associated with the support member 152 for use to mount the support member 152 to a side of a vehicle, such as to a Toyota RAV4. In some examples, fewer than three or more than three attachment points 154 may be provided with the support member 152 for mounting the support member to the vehicle. Further, each attachment point 154 may have one or more brackets 158 and one or more frame locking bolts (FLBs) 160. In the embodiment shown, one of the attachment points 154 has one bracket 158 and one FLB 160, another attachment point 154 has two brackets 158 and two FLBs 160, and the third attachment point 154 has a three brackets 158 and three FLBs 160. However, the number of attachment points 154 and the number of brackets and FLBs for use at each attachment point can vary. For example, there can be three attachment points 154 with each attachment point having only one bracket and one FLB or each attachment point having two brackets and two FLBs.

In an example, each bracket 158 comprises an upper bracket section 158 a, a lower bracket section 158 b, and a base bracket section 158 c. The upper and lower bracket sections 158 a, 158 b can extend from the base bracket section 158 c. In some examples, the sections of the bracket 158 are unitarily formed, such as by extruding and cold working or by welding different sections together. The bracket 158 can attach directly to the support member 152. For example, the base bracket section 158 c can be welded or secured to the support wall 126 or one of the walls of the support member 152. In other examples, the brackets 158 for use with the support member can differ, such as having only a single bracket section or more than three bracket sections.

In an example, as disclosed in the '919 patent, previously incorporated by reference, the support member 152 may have channels or bolt galleys and the base bracket section 158 c can have a bolt head extending therefrom and slidable within one of the channels or bolt galleys and be re-positionable there along. Once the anchor connected to the bracket 158 is located at a desired location on the support member 152, the bracket 158 can be more permanently secured to the support member 152, such as by torquing a nut to a bolt screw to secure the bracket to the support member.

As further discussed below, the frame locking bolts (FLBs) 160 of the present invention are particularly configured for blind installations, or installations in which the installer does not have access to different ends of a bolt and nut for threading. The bracket 164 disclosed herein for use with the FLB 160 facilitate alignment and orienting between the two to facilitate installation, as further discussed below. The FLB 160 in combination with a bracket 164 in accordance aspects of the invention, which can be called an adapter bracket to distinguish from other brackets, define a mounting point for attaching to a support bracket 158 that is attached to the support member 152 to then mount the support member to the vehicle. Each attachment point 154 is therefore understood to include an adapter bracket 164 attached to the vehicle and a mounting bracket 158 attached to the support member 152 and the two brackets are held together by an FLB 160. An optional traditional bolt and nut combination 166 may be used to further fasten the two brackets together to provide an additional connection point.

With reference now to FIGS. 10 and 11, which show a close-up perspective view and an end view of the support device 100 of FIG. 9, an attachment point 154 is better shown having an adapter bracket 164, a mounting bracket 158, which has an upper bracket section 158 a and a lower bracket section 158 b, and an FLB 160. Also shown is an optional bolt and nut combination 166, which may be referred to generically as a fastener. The fastener 166 is preferred to provide an additional secured point between the two brackets 158, 164. The support member 152 shown is a running board but can alternatively embody a rock rail 102, 102′ as shown with respect to FIGS. 1-5.

As further discussed below, the adapter bracket 164 and bolt of the FLB 160 can first be installed or mounted to the bottom of a vehicle, typically in a blind installation. Then once the adapter bracket 164 and the bolt of the FLB 160 are in place, which together can define an adapter point 165, then the combination support anchor 158 and support member 152 can be brought together with the adapter point 165 and secured thereto by tightening or torquing onto a nut of the FLB, as further discussed below. In some examples, as previously discussed, there can be more than one attachment points 154, more than one adapter points 165, and more than one mounting brackets 158 for securing the support member 152 to the vehicle. The adapter bracket 164 and the FLB 160 may be made from a metal material, such as steel, stainless steel, or aluminum.

With particular reference to FIG. 11, the FLB 160 of the present embodiment has a standard bolt 170 with a bolt head 170 a and a threaded stem or threaded shank 170 b, a nut 172 for threaded engagement with the threaded stem, and a bolt head flange 174. A spacer 176 and a pin 178 connected to or attached to the spacer may be used with the FLB 160. In the example shown, the bolt head flange 174 is secured to the bolt head 170 a so that the two move together, and are fixed to one another. In an example, the bolt head 170 a and the bolt head flange 174 can be welded together, such as with one or more spot welds, or less preferably a long continuous weld. The spacer 176 has a bore and is slidable or movable axially along the length of the threaded stem 170 b.

The spacer 176 can have a second bore. The pin 178 can be press fitted into the opening of the second bore of the spacer 176 and can project through an opening on the bolt head flange 174. By using the pin 178 and projecting the pin into the opening 198 (FIG. 14) of the bolt head flange 174, the spacer 176 and the bolt head flange 174, and therefore the bolt head 170 a, can be angularly aligned relative to one another, with some small play being acceptable due to the relative size of the pin and the opening on the bolt head flange.

As further discussed below, the pin 178, or similar structures for aligning the bolt head flange with the spacer, forces the orientation of the bolt head flange 174 from a location below or remote from the bolt head flange. That is, after the bolt head flange 174 and bolt 170 are situated in place in a blind installation, the bolt head flange 174 can orient a number of different angular positions, restricted by only the surrounding physical structure, if any. From a location below the bolt head flange, the spacer 176 with the pin 178 can be located onto the threaded shank 170 b and then moved toward the bolt head flange 174 to project the pin 178 through the opening 198 (FIG. 14) on the bolt head flange. This process either forces the bolt head flange 174 to be rotated, such as by rotating the threaded shank 170 b, so that the pin 178 can project through the opening 198 (FIG. 14) or the bolt head flange can be rotated after the pin 178 projects through the opening by observing the location of the pin, or other marker on the shank or the spacer, to orientate a certain way. Then the adapter bracket 164 can be slid between the spacer 176 and the bolt head flange 174. This process further allows the bolt head flange 174 to be angularly aligned with the adapter bracket 164, such that the edges, length, or side of certain part of the bolt head flange to align with the edges, length, or side of certain part of the adapter bracket. The alignment can be to within certain angular rotations due to size of play of the various parts.

Thus, after the bolt head 170 a, the bolt head flange 174, and the adapter bracket 164 are placed in position in a blind installation on an underside of a vehicle, as further discussed below, the relative angular positions of the bolt head flange 174, bolt 170, spacer 176, and adapter bracket 164 can be certain or ensured by features of the present FSB 160 and adapter bracket 164. The technician can now turn the nut 172, after mounting the bracket on the support member 152 onto the threaded stem 170 b, to secure the support member to the vehicle. In a less preferred embodiment, the pin 178 can be omitted and a marker or indicia located on the bolt 170, such as a score line, a paint mark, etc. on the threaded shank 170 b, can be utilized to angularly align the bolt head flange 174 and the adapter bracket 164.

FIG. 12 is a perspective view showing the frame locking bolt (FLB) 160 and adapter flange 164 of FIGS. 10 and 11. As shown, the adapter bracket 164 has a first mounting section 182 for engaging with the FLB 160, a second mounting section 184 for engaging the fastener 166, and an intermediate section 186 located between the first and second mounting sections. In an example, the first and the second mounting sections have surfaces defining planes that are parallel to one another. In some examples, the two mounting sections 182, 184 can be angled to one another. The first and second mounting sections 182, 184 can be selected with parallel surfaces or surfaces that are angled to one another depending on the structures or components that the adapter bracket 164 is intended to fit against or into, such as for use of a Toyota RAV4 instead of a Subaru Outback.

In an example, the intermediate section 186 has an angled surface or is angled relative to the first mounting section 182, the second mounting section 184, or to both mounting sections 182, 184. The slope and the length of the intermediate section 186 can vary for fit with the vehicle in question. In other examples, the intermediate section 186 is vertical and has no slope. Still further, the intermediate section 186 may incorporate a bend or inflection point 183 to change the position of the second mounting section compared to when the intermediate section does not incorporate any bend or inflection point. The bend or inflection point 183 can add structural rigidity by functioning as a reinforcement member, such as a rib. In the present embodiment, the location of the inflection point 183 on the intermediate section 186 can be selected to abut or support a structure that the adapter flange 164 is located. For example, the inflection point 183 defines a surface 185. When the adapter flange 164 is located on a vehicle, the pinch weld 12 (FIG. 1) of a unibody vehicle can rest on the surface 185. Said differently, the adapter flange 164 can be located in the mounting space of a vehicle and arranged so that the surface 185 of the inflection point 183 is butted up against the low end of the pinch weld 12. This way, any point load acting up on the running board, and hence the adapter flange 164, can be distributed over a broader area and to a strong area of the unibody frame, as previously discussed.

With further reference to FIG. 13, the adapter bracket 164 is shown without the FLB 160 and without the fastener 166. As shown, the first mounting section 182 has a channel or a slot 188 formed at about a mid-point of the width of the first mounting section 182 to a depth that is about 20% up to about 80% of the length of the first mounting section 182. The entrance to the slot 188 may be widened or flared and the width of the slot may be sufficiently wide to facilitate passing the threaded stem 170 b of the bolt 170 therein, as shown in FIG. 12. The bolt, such as the threaded stem, may be located anywhere along the length of the slot 188 during initial and/or final assembly. However, the length of the slot 188 can be selected to ensure that the final assembly position of the bolt 170 is located at a desired position relative to the first mounting section 182. Further, the width of the slot 188 can be selected to not only facilitate passing the threaded stem 170 b through during installation but turning of the combination threaded stem 170 b and pin 178 within the slot. For example, the tighter the fit, the less the threaded stem and pin will turn within the slot 188 but will make passing the stem more difficult. Further, the size of the pin 178 and the location of the pin 178 relative to the threaded stem 170 b can affect the angular rotation of the threaded stem within the slot.

In an example, one or more beads or projections 190 may be incorporated on the top surface of the first mounting section 182. As shown in FIG. 13, a bead or projection 190 may be located on each side of the slot 188. In some examples, a third bead may be incorporated at the end of the slot 188, forming a three point bead-configuration near the end of the slot 188. The beads 190 are configured to project into or be located within a perimeter defining an opening that the threaded stem 170 b is positioned under a vehicle. This in turn sets the location and angular position of the adapter bracket 164 relative to the opening of the frame of the vehicle. In some examples, only one bead 190 is incorporated. Less preferably, no bead is incorporated on the top surface of the first mounting section 182 of the adapter bracket. Alignment and positioning of the adapter bracket for the embodiment without any bead can be processed or controlled based on the relative size of the slot 188 and the bolt 170, as well as the length or dimension of the first mounting section 182. For example, by selecting the length of the first mounting section 182, the distance between the intermediate section 186 and the edge of the first mounting section at the entrance of the slot can be controlled. This in turn controls the relative position of the intermediate section relative to the pinch weld or relative to the depth of the slot, etc.

A hold down hole 192 is provided with the second mounting section 184 of the adapter bracket 164. In an example, the hold down hole 192 is generally oval or elongated to provide adjustability, by allowing the shank or threaded stem of the fastener to position along the length of the opening 192. The hold down hole 192 may be located around a midway point on the second mounting section 184 to provide a second securement point for securing a mounting bracket 158, as shown in FIG. 10 and further discussed below.

FIG. 14 shows a frame locking bolts (FLBs) 160 in accordance with aspects of the invention, which can be made from a metal material. The FLB 160 comprises a bolt 170 with a bolt head 170 a and a stem or shank 170 b, a bolt head flange 174 secured to the bolt 170, and a nut 172 for threaded engagement with the shank 170 b. The size and length of the bolt 170 can be selected as needed for the particular application. As shown, the bolt head flange 174 has an opening 194 through the body of the bolt head flange 174 for receiving the threaded shank 170 b. A weld bead 196 is provided at the intersection of the bolt head 170 a and the bolt head flange 174 to permanently secure the two to one another. Two or more weld beads can be incorporated. Thus, the bolt and the bolt head flange are fixed as an integrated unit.

A second opening 198 can be provided through the body of the bolt head flange 174, spaced from the first opening 194. As shown, the second opening 198 has a smaller opening size than the opening diameter of the first opening 194. The second opening 198 is sized and shaped to accommodate a pin 178, which can pass through the second opening 198 from the shank side towards the bolt head side of the bolt head flange 174 and has a smaller diameter than the threaded shank 170 b. In an example, the body of the bolt head flange 174 is provided with a tip 200 having a ramp or a tapered surface. The tip 200 with the ramp can facilitate assembly of the combination bolt and bolt head flange in through an opening of an automobile frame. The ramp can be incorporated, for example, to fit within a certain shaped automobile frame. In other examples, the ramp can be omitted at the tip 200. In yet other examples, the edge of the tip 200 can be generally square instead of rounded as shown.

In an example, the spacer 176 is provided as a generally cylindrical body 202. In one example, the body 202 can have a single diameter elongated solid cylinder with a central bore 204 for accommodating the threaded stem 170 b. In the embodiment shown, the body 202 of the spacer 176 is provided with a step 176 c, thereby producing a first body portion 176 a and a second body portion 176 b. The second body portion 176 b can have an outside diameter that is larger than the outside diameter of the first body portion 176 a. The diameter of the first body portion 176 a, and the height or thickness, can be selected for fit. For example, when mounting the FLB 160 to a vehicle, the diameter of the first body portion 176 a can be selected to project in through an opening in the frame of the vehicle where the threaded stem 170 b is located.

The spacer 176 is further provided with a second bore 208 for receiving the pin 178 in a press fit. In an example, the second bore 208 has an opening at the top surface of the first body portion 176 a and the bore extends through at least part of the height or thickness of the first body portion. In a particular example, the second bore 208 extends through at least part of the height or thickness of the second body portion 176 b. The second bore 208 on the spacer 176 should be aligned with the second opening 198 on the bolt head flange 174 so that when the pin 178 is located in the second bore 208 of the spacer 176 and the spacer 176 is brought in close proximity or in contact with the bolt head flange 174, the pin 178 projects through the second opening 198 of the bolt head flange 174. This configuration allows the spacer 176 to turn relative to the bolt head flange 174, and vice versa, when the pin 178 does not project through the second opening 198 of the bolt head flange 174, such as during initial installation of just the bolt 170 and the bolt head flange 174, and to be angularly fixed relative to the bolt head flange 174, to within acceptable tolerance, when the pin 178 projects through the second opening 198 of the bolt head flange 174. The two noted conditions can be referred to as a first condition and a second condition.

FIG. 15A shows a perspective top view of the spacer 176 and pin 178 and FIG. 15B shows a cross-sectional side view of the spacer 176 and pin 178. As shown, the pin 178 is press fitted into the second bore 108. While the second bore 208 is a through bore, like the first bore 204, the pin 178 terminates short of or even to the inside opening 220 to the second bore 208.

A recess 224 can be provided at the second body portion 176 b. The recess 224 is optional for optionally receiving a retaining plastic or nylon retaining washer 228 (FIG. 16C). The retaining plastic washer 228 can be used to engage the threaded stem 170 b of the FLB to temporarily hold the spacer 176 in place during installation, such as to prevent the spacer 176 from slipping or falling down due to gravity before the nut 172 is threaded onto the stem 170 b. Once the nut 172 is threaded onto the threaded stem 170 b of the FLB 160, the plastic or nylon washer 228 can remain in place within, or at least partially within, the recess space 224.

With reference now to FIGS. 16A-16D and initially to FIG. 16A, a partial cross-sectional end view of an underside of an automobile 10 is shown. In particular, an underside of a partial exemplary unibody chassis 230 is shown, such as a Toyota RAV 4. The chassis 230 can have a number of welded metal sheets, including a first lower metal sheet 232 forming part of the side sills, a second lower metal sheet 234, third lower metal sheet 236, a fourth lower metal sheet 238 forming part of the side sills of the unibody chassis 230. The exemplary chassis 230 can also include a body cladding piece 240, which can be a thin layer metal sheet, such as aluminum or steel, or can be a plastic cladding piece. The first lower metal sheet 232 can have a hole or an opening 244 that opens into an interior hollow cavity or space 246. The opening 244 can be round, typically in the order of about 0.75 inch to 1.5 inch. The body cladding piece 240 can also have a hole or an opening 248 aligned with the opening 244 on the first lower metal sheet 232.

The bolt head 170 a and the bolt head flange 174 of the FLB 160 can be placed through the two openings 244, 248. The opening 248 on the body cladding piece can be a rocker panel hole on most vehicles. The end of the bolt head flange 174 without the slot can be angled first in through the two openings and then the bolt 170 is allowed to rest with the lower surface of the bolt head flange 174 resting on the inside of the lower metal sheet 232.

With reference now to FIG. 16B in addition to FIG. 16A, the adapter bracket 164 can then be inserted between the first lower metal sheet 232 and the body cladding piece 240. The slot 188 (FIG. 13) on the adapter bracket 164 is aligned to receive the threaded stem 170 b. The body cladding piece 240 is sufficiently flexible to enable a technician to manipulate it during installation of the adapter bracket 164. Once positioned as shown, the two beads 190 on the upper surface of the first mounting section 182 of the bracket 164 (FIG. 13) are located within the opening 244 of the first lower metal sheet 232. The two beads 190 keep the adapter bracket 164 from moving laterally and align or center the beads 190, and therefore the bracket 164, relative to the opening 244 of the first lower metal sheet 232.

In an alternative method for installing the adapter point 165 (FIG. 11) of the present invention, the spacer 176 with the pin 178 located therein or thereon (FIGS. 14 and 15B) is mounted onto the threaded stem 170 of the FLB prior to installation of the adapter bracket 164. For example, the spacer 176 can slide onto the threaded stem 170 b and the pin 178 can project through the second opening 198 of the bolt head flange 174 (FIGS. 12, 14). During this alternative process, the nylon washer 228 (FIG. 16C) can retain the spacer 176 in place and prevent gravity from acting on the spacer. A maker or indicia may be provided on the threaded shank 170 b to provide guidance during installation of the spacer 176. The adapter bracket 164 can then be mounted as previously described, after projecting the pin 178 into the second opening 198 of the bolt head flange 174 (FIG. 12). The alternative method has the advantage of aligning the FLB 160 prior to installation of the adapter bracket 164. Thus, once the adapter bracket 164 is inserted between the first lower metal sheet 232 and the body cladding piece 240, the adapter bracket 164 and the slot or channel 188 on the bracket are also aligned to the FLB 160.

In yet another alternative installation embodiment, the spacer 176 is first mounted onto the threaded shank 170 b but not pushed up to project the pin 178 in through the second opening 198 of the bolt head flange 174. The FLB 160 is then inserted through the opening 248. The adapter bracket 164 is then inserted by pushing or pulling onto the body cladding piece 240, which in practice can be a plastic rocker panel.

FIG. 16C shows the bracket 164 located between the first lower metal sheet 232 and the body cladding piece 240 and the spacer 176 slid up against the body cladding piece 240 so that the pin 178 projects through the second opening 198 of the bolt head flange 174 (FIG. 14). In this position, the nylon washer 228 is relied on to temporarily hold the spacer 176 in position. Note that the first body portion 176 a (FIG. 14) of the spacer 176 is sized and shaped to project through the opening 248 on the body cladding piece 240 so that the upper surface of the spacer 176 contacts the adapter bracket 164. This ensures a solid and secured connection of the FLB 160 and adapter 164 once the nut 172 (FIG. 14) is threaded onto the threaded shank 170 b and tightened.

FIG. 16D shows the final mounting step to mount the running board 100 of FIG. 8 of the present invention onto a vehicle using an FLB 160 of the present invention. With reference to FIG. 16C in addition to FIG. 16D, and assuming that all necessary FLBs 160 and adapter brackets 164 have now been installed onto the vehicle 10, the running board 100 is then brought up to the adapter points 165 (FIG. 11) while making sure to align the opening on the upper bracket section 158 a with the threaded shank 170 b on the FLB. The nut 172 is then threadedly secured to the shank 170 b by accessing the opening 254 on the lower bracket section 158 b. Note that once the running board 100 is brought up to the adapter points for final installation on the vehicle, the bolt head, the bolt head flange, the spacer, the pin, and the adapter bracket are hidden from view. However, by incorporating features described herein, the bolt head, the bolt head flange, the spacer, the pin, and the adapter bracket are aligned and properly installed. All the technician has to do next is to fasten the final nut 172 onto the threaded stem 170 b.

For added security, a fastener 166 can be used to secure the adapter bracket 164 with the mounting bracket 158 on the running board 100. This process can be repeated for the number of brackets 158 and FLBs 160 incorporated with the running board 100.

The support member 152 is shown with a thermoplastic or rubber insert 260 mounted onto the top surface of the support member. In an example, the insert 260 has male detents 262 that can snap into bolt galleys 264 on the running board 152 to provide a non-metallic step cushion for added gripping during ingress and egress from the vehicle. Of course, the insert 260 may be omitted or a different type of inserts may be used.

The foregoing describes an FLB and adapter bracket for use in a blind application for mounting a running board to an underside of a vehicle. The apparatus and process can be carried out as an after-market running board and tools for mounting the after-market running board onto a vehicle, such as a Toyota RAV4, a Subaru Outback and Forester, or other SUVs, trucks and cross-overs.

In some examples, the support member 152, frame locking bolts 160 and adapter brackets 164 shown and described herein are provided in one or more shipping cartons or packages along with instructions for mounting onto an underside of a vehicle. The vehicle owner can mount the support device as a do it yourself project or can take the assembly to a car garage to be installed.

Methods of making and of using the support devices and their components described elsewhere herein, including the disclosed frame locking bolts and adapter brackets, are understood to be within the scope of the present disclosure.

Although limited embodiments of support devices and assemblies and their components have been specifically described and illustrated herein, many modifications and variations will be apparent to those skilled in the art. For example, the various support devices may incorporate custom paint, have different outer contoured shapes, provided with metallic overcoats, etc. Furthermore, it is understood and contemplated that features specifically discussed for one support device embodiment may be adopted for inclusion with another support device embodiment, provided the functions are compatible. Accordingly, it is to be understood that the support devices and assemblies and their components constructed according to principles of the disclosed device, system, and method may be embodied other than as specifically described herein. The disclosure is also defined in the following claims. 

What is claimed is:
 1. A support device for a vehicle comprising: a support member defined by a plurality of walls including a support wall, the support member being elongated and including: a pinch weld channel having a support surface and at least one extended side wall extending from the support surface; a side channel spaced from the pinch weld channel; wherein the pinch weld channel is located above, elevation-wise, the support wall and the support wall extends from the support surface at an angle to the support wall; and wherein the side channel has a recessed groove for receiving a gap filler.
 2. The support device of claim 1, wherein the support wall comprises an I-beam cross sectional shape.
 3. The support device of claim 1, further a bracket welded to or secured to the support member, the bracket having a mounting flange for mounting the support member to an underside of a vehicle.
 4. The support device of claim 2, further comprising two or more brackets welded to the elongated support member or fastened to the elongated support member.
 5. The support device of claim 1, further comprising a non-metallic gap filler located in the pinch weld channel.
 6. The support device of claim 5, further comprising a non-metallic side gap filler having a head portion and a stem portion, and wherein said stem portion is located in the recessed groove of the side channel.
 7. The support device of claim 1, further comprising a rib wall located internally of a body defined by the plurality of walls, said rib wall attached to one of the plurality of walls of the support member.
 8. A support device for a vehicle, said support device comprising: an extruded metallic support member having a body with a length and a top wall having a top wall with a top surface, a top wall first end, and a top wall second end; a rigid extension extending above the top wall top surface at the top wall first end; a side channel having a recessed groove located at the top wall second end and spaced from the rigid extension; a load bearing structure located directly below, elevation-wise, the rigid extension having a surface for transferring a point load on the surface to the rigid extension; wherein the rigid extension has a terminal end that is located above, elevation-wise, the side channel when the support device is mounted to a side of a vehicle.
 9. The support device of claim 8, wherein the load bearing structure comprises an I-beam cross sectional shape.
 10. The support device of claim 8, wherein a sloped sidewall is located below, elevation-wise, the side channel.
 11. The support device of claim 9, further comprising a bracket coupled to or welded to the support member, said bracket having a flange for attaching the support member to a vehicle.
 12. The support device of claim 10, further comprising a step extending laterally from the elongated support member.
 13. The support device of claim 8, further comprising an edge guard located at the terminal end of the rigid extension.
 14. A support device for a vehicle comprising: an elongated support member having two ends and a sidewall; a bracket fastened to or welded to the sidewall of the support member; a threaded shank of a bolt projecting through an opening of the bracket; a bolt head welded to a bolt head flange and the threaded shank extending from the bolt head; a spacer located between the bolt head and the bracket, and a pin extending from the spacer and through the bolt head flange, said pin being spaced from said threaded shank.
 15. The support device of claim 14, wherein the pin is press fitted to a bore in the spacer and extends through an opening in the bolt head flange.
 16. The support device of claim 14, wherein the spacer has a body with a first body portion having a first diameter and a second body portion with a second diameter, and wherein the second diameter is larger than the first diameter.
 17. The support device of claim 14, further comprising an adapter bracket having a first mounting section located between the spacer and the bolt head flange.
 18. The support device of claim 17, wherein the adapter bracket has a slot formed at the first mounting section.
 19. The support device of claim 18, where the first mounting section has a top surface and wherein a bead is located at the top surface adjacent the slot.
 20. The support device of claim 19, wherein the adapter flange further comprises a second mounting section spaced from the first mounting section by an intermediate section. 